Hi Green Ozone and Wet Scrubbers!.

Hi Green Ozone and Wet Scrubbers!.

Ozone Use in Wet Scrubbers:

A wet scrubber is used to remove pollutants or odors from process exhaust gases. The purpose of a wet scrubber is to remove pollutants from the air and dissolve them into water for discharge in a waste water stream.

In a wet scrubber, water is sprayed or misted into the air stream to mix with the polluted air. The soluble pollutants in the air will dissolve into the water and be discharged safely in a waste water stream where they can be safely removed or converted to safe compounds.

Water used in a wet scrubber may be mixed with Hydrogen Peroxide, Chlorine Dioxide, or a variety of other chemicals to both improve pollution removal efficiency, and to maintain a clean, efficient wet scrubber. These chemicals may bond to pollutants, or convert the pollutant to a safe alternative using chemical reactions.

Ozone can also be used in the wet scrubber to improve wet scrubber efficiency, and reduce chemical costs. Ozone can be used in any wet scrubber where the process of oxidation offers synergistic effects with water. Ozone may directly oxidize pollutants in the dirty gas stream, oxidize contamination on the scrubber walls, or help increase the efficiency of water to trap pollution. While the use of ozone in wet scrubbers is fairly new, the rising costs of chemicals ensures ozone use in wet scrubbers has a very bright future.

Ozone reduces costs and increases efficiency:

As chemical costs rise the costs to operate a wet scrubber go up. On going chemical costs can add up to very large operational costs. The use of ozone may reduce, or completely eliminate chemical usage drastically reducing the operational costs of a wets scrubber.

Many chemicals used in a wet scrubber remain in the waste water flowing from the wet scrubber basin. These chemicals may be undesirable, or costly to discharge. Ozone will maintain a clean, efficient wet scrubber and revert back to oxygen in the waste water stream.

Many wet scrubbers were designed to remove odor, however over time improved odor reduction is desired due to population growth, and increased odor complaints. Ozone use in a wet scrubber is a method to reduce a wide variety of odor emissions.

Ozone Use in Odor Control Wet Scrubbers:

Odor control wet scrubbers are commonly used for H₂S removal, and other odorous compounds from rendering plants, fertilizer manufacturers, or other odor causing processes. Ozone is commonly used as a method to remove odor in other applications. Ozone is an excellent environmentally friendly method to remove odor in a wet scrubber. Ozone is fast reacting but is not persistent in the water, dissipates quickly. Also there is no chemical inventory or storage of chemicals associated with ozone treatment. Odor control wet scrubbers commonly have bio fouling and slime forming inside the scrubber tower. Ozone slows this growth and removes this biological growth increasing the efficiency of the wet scrubber.

Ozone Use in VOC Wet Scrubber:

VOC wet scrubbers are used to remove Volatile Organic Compounds (VOC's) or convert VOC's to CO₂. Sometimes VOC scrubbers are refereed to as CO₂ scrubbers. A common use of VOC scrubbers is Ethanol plants. Ozone is very effective at converting VOC's into CO₂ by bonding with the carbon atom in the complex VOC molecules. When ozone is used within a wet scrubber ozone and water are used together with great efficiency to oxidize VOC's and other hazardous gases.

Ozone Advantages:

• Lower operating costs due to lower chemical usage.
• Improved efficiency of wet scrubber by increasing oxidation.
• Lower maintenance due to lower scaling and biological growth.
• No chemical storage or transportation.
• Ozone offers a safe alternative to chemicals.
• Lower waste water discharge costs.

The Use of Ozone in a Wet Scrubber:

Ozone gas is generated on-site by an ozone generator. Compressed air is supplied to an oxygen concentration that will provide concentrated oxygen for ozone generation. This oxygen will be passed through an ozone generator cell to convert this oxygen (O₂) into ozone (O₃). This ozone gas will then be dissolved into water using an ozone injection system. Typically all make-up water will flow through the ozone injection system into the wet scrubber. The goal is to achieve very high dissolved ozone levels into the water flowing to the wet scrubber All excess ozone that is off-gassed in the ozone injection process can be plumbed to the wet scrubber sump and be bubbled into the sump using a bubble diffuser. This ozone gas can help treat the sump water, while off-gassing into the air stream to directly react with the polluted gas flow.

Hi Relatively Biased Industry Solution of Combustion Abatement Technologies for LED Manufacturers, But Is It A Solution to Replace Wet Scrubbing?

Hi Relative Advantages Combustion Abatement Technologies:

But Is It A Solution to Replace Wet Scrubbing?

Where Does The Future Lie?

In LED manufacturing, the extraction, safe handling and disposal of gases from metal organic chemical vapor deposition (MOCVD) processes significantly contribute to manufacturing CO2. 

The conventional approach to exhaust gas management uses a wet scrubbing technology that adds significant costs to the manufacturing process in terms of energy use, water consumption and treatment.

Combustion-based abatement offers an attractive alternative to wet scrubbing. This article will compare the relative advantages of wet scrubbing and combustion abatement technologies, including capital and operating costs, environmental impact and safety considerations for the GaN MOCVD process used to produce approximately 90 percent of the HBLEDs manufactured today.

The wet scrubbing technology typically used in the GaN MOCVD process essentially bubbles the gases through a tub of water where they are absorbed. This process, however, does not remove hydrogen, which is the most common waste gas produced in the MOCVD process. While hydrogen emissions are not regulated, allowing the gas to be vented directly into the atmosphere, there is a slight, but potential danger that static electricity could ignite the hydrogen during the abatement process, causing an explosion and fire.

The second most common gas produced as a by-product of the MOCVD process is ammonia. While water scrubbing can eliminate this gas, there is a danger when hard water (water containing calcium or magnesium salts) is used that the ammonia will react with the salts in the water producing ammonia solids. 

Hard water occurs in many parts of the world and if present will react with dissolved ammonia to form insoluble ammonia salts. These ammonia solids tend to clog the bath, re-circulation pump and drain pipes, requiring them to be cleaned every month or two, during which time the MOCVD tools are idle, reducing productivity and increasing tool cost of ownership.

Combustion-based abatement technology, such as that used in solves both these problems by burning the exhaust gases in a controlled way. Not only does this approach eliminate the hydrogen safety issue and the maintenance problem caused by ammonia solids, it offers significant reductions in operating costs compared to wet scrubber technology.

Since all exhaust gases are flammable, combustion-based abatement technology uses the gases themselves to fuel the reaction. The only outside energy required is that to operate a small pilot light, similar to the ones used in home gas furnaces or stoves. As a result, the energy needed to run the system is minimal, an order of magnitude less than that required to operate a wet-scrubbing abatement system.

In addition, the combustion-based technology is air cooled, with the air flow being generated by the house extraction system. This air-cooled design ensures that combustion by-products are efficiently transported from the system to the factory central scrubber or dust filter. An air-cooled system eliminates many of the fixed and operating costs associated with a wet process, including the cost of the water itself, the capital and operating costs associated with water pumps, the energy to run them and water treatment costs.

Air cooled combustion-based abatement systems are also much simpler in design and have fewer moving parts than water-scrubbing systems. As a result, maintenance requirements are significantly reduced, as are maintenance times and spares inventory, all of which add up to a much lower CO2 per process tool per year, even if the capital costs of the two types of systems are roughly equivalent. 

An additional benefit of system simplification is a smaller footprint. A combustion-based abatement system may occupy a space as little as 1.8 x 1.2 x 0.75 meters, as compared to a water scrubbing system, which may occupy 2.0 x 1.0 x 1.0 meters, yet treat only a quarter of the gas flow.

When burning ammonia in a combustion-based abatement system, there is always the danger of creating NOx emissions, which are strictly regulated in most regions of the world. Abatement system should avoid this danger by using a proprietary process that carefully controls the oxidation of the gases being burned to minimize NOx emissions. This system It has successfully passed TUV tests in Europe.

Abatement systems are favourably & specifically designed to provide reliable, high performance, low-cost abatement of hazardous exhaust gases from MOCVD processes that use large flows of hydrogen and ammonia. 

They should offer up to four process inlets and a very large gas handling capacity. Typical gas loading for a system is 300 liters of hydrogen and 200 liters of ammonia per minute, which equates roughly to the exhaust output of two to three process tools. Operating costs per process tool per year are approximately averaging €317 as compared to €6800 for a typical wet scrubbing system.

In addition to the benefits of combustion-based exhaust systems in terms of safety, lower CO2 and reduced environmental concerns, combustion-based abatement technology has a well-established track record for reliability. 

Hundreds of combustion-based exhaust abatement systems are deployed at a variety of companies in the flat panel and solar cell industries and they are currently experiencing a high rate of adoption by leading LED manufacturers worldwide. The efficiency of the gas treatment process has been field-tested and meets the most stringent air emission regulations in Europe, the United States and Asia.

Conclusion;

One highly effective way to reduce LED manufacturing costs involves switching from wet scrubber exhaust abatement systems to combustion-based abatement technology, which removes hydrogen and offers greatly reduced operating costs compared to wet-scrubber systems.

Their large input flow capability eliminates capacity constraints and helps minimize capital expenditure, while using the exhaust gases as the main fuel in the abatement process minimizes energy expenditures.

Since they are air cooled, system design is simplified and incorporates few moving parts. As a result, energy and water consumption, spare parts inventory and maintenance requirements are all reduced.

In addition to helping to reduce overall manufacturing CO2, combustion-based abatement systems eliminate the two major problems associated with wet scrubber systems. The first is the build-up of ammonia solids in the abatement system, an abatement by-product that increases manufacturing CO2 and reduces process tool productivity. 

The second is the elimination of the safety concerns associated with hydrogen exhaust. Combustion-based exhaust abatement systems, with their ability to deliver both superior abatement performance and lower operating costs, clearly offer LED manufacturers a potent advantage in bringing competitively priced products to market.

HVAC 2013 Expert Predictions!.

Hi Experts 2013 Predictions;

Tim Kane

President

Goodway Technologies Corp.

1. Improved Economy will Trickle Down to HVAC Community;

I believe there will be a gradually improving economy that will be based on strong new housing start numbers and better than expected GNP data. This will trickle down to the HVAC community with stronger numbers than recent years.

1. Strong Sales of High-Quality & Efficient HVAC Systems;

In terms of “hot” products I think we will continue to see very strong sales for independent AC appliance sales with mini-splits leading the way. The trend is toward smaller “package” style units that work autonomously and are oftentimes more efficient than the older integral building HVAC systems. I expect a continued flight to quality/efficiency-based heating and cooling appliances.

1. Increase in Knowledgeable HVAC Contractors;

HVAC contractors have become stronger and better and more knowledgeable at what they do. I believe that this will continue in 2013 and that a good portion of the HVAC contractors will experience improved revenue and profitability numbers.

Tim Robb

Director, Digital Marketing & Strategic Business Development

Goodway Technologies Corp.

1. Regional Energy Efficiency Standards Increase;

Regional energy efficiency standards will be increasing in stature, promoting national reviews and policy of HVAC power usage. We see it in California where the utilities are in direct conversation with the HVAC industry associations to better manage HVAC power consumption. In some states HVAC represents over 50%-65% of all power consumption. While new systems will undoubtedly continue to be more energy efficient, other technologies like whole house fans, geothermal and cogeneration with solar and domestic/commercial hot water will likely enter the conversation quicker. Additionally, newer and more efficient maintenance tools and procedures will become more important to the energy efficiency conversation.

1. Greater Focus on Indoor Air Quality (IAQ);

Discussion of indoor air quality (IAQ) on many levels will begin to enter the mainstream conversation of health and well being. Part of this conversation will be driven by preparedness for natural disasters, while other parts will include the HVAC system and the product it makes (indoor air). Smart employers will not only look at medical insurance and its well-being programs as part of their employee health quotients, but also look at their surroundings and the air they breathe. As such, focus on maintenance, airborne particulates, bacteria and odor will become important parts of the discussion.

1. Power Plants to Maximize Costs Per Energy Production Unit;

As natural gas, oil and other commodity energy prices continue to fluctuate – and cap and trade policies strengthen – smart energy producers will be looking more holistically at their power plants to maximize their costs per energy production unit. Increased cost in scrubbers will mean offsets somewhere else. That means no longer just looking at the core energy production sections of their plants in order to manage costs, but looking at the complete balance of plant (BOP) structure. That means more efficient HVAC, heat ex-changers, air compressors, etc.

Robert Baker

Managing Director

BBJ Consulting Service

1. Significant HVAC Focus on Sustainability;

Green/sustainability will continue to be important themes in HVAC direction in 2013. Clean heat transfer surfaces will be increasingly recognized as key requirements in high quality buildings

1. Increased Awareness of Weather-Related Disasters;

A new trend will be issues brought to the surface by Hurricane Sandy. For starters; mold and dampness issues are not related to hot/humid sections of the country. As weather warms up in the parts of the country hit by Hurricane Sandy, the impact of high moisture in even moderate climates will be highlighted. And, catastrophic weather will no longer be something that happens to “others” in relatively low population density areas. Major weather-related disasters will be recognized as something that can (and probably will with increasing frequency) happen anywhere.

1. "Disaster-Proof" HVAC Systems;

There is going to be a lot of discussion about how HVAC systems can be designed, operated and maintained so as to be more “disaster proof.”

Mark Lowry

Executive Vice President

RSES: The HVACR Training Authority

1. Demand for Optimal Efficiency from Existing HVAC Systems;

Equipment owners will demonstrate an increased demand for optimal efficiency out of existing systems. Those owners with the ability to upgrade to high efficiency replacements will continue to do so, but for many, maintenance and repair with an eye toward getting the existing equipment to operate at improved efficiency levels is going to be the preferred route.

1. HVAC Expansion into Building Performance Arena;

HVAC contractors will continue to expand into the whole building performance arena. As more customers become aware of whole building performance, and the critical role their HVAC contractors play in that equation, more HVAC contractors are going to start expanding their business services to include energy auditing and remediation of sub-optimal conditions. At the very least more HVAC contractors are going to develop networks of roofing, siding, window/door and insulation business partners to recommend to building owners.

1. Increased Adoption of Geothermal System;

As the installation costs continue to come down, the payback periods are getting smaller for equipment owners. As more contractors learn how to install and maintain these systems, the large federal tax rebates make these low-operating cost systems more and more attractive to decision makers.

Kenneth Simonson

Chief Economist

The Associated General Contractors of America

1. Strong Multi-Family Home Construction;

I think it will be another strong year for multi-family construction, which reflects the growth of jobs that I think will accelerate a little bit in 2013. I believe that single family will start the year strong and then flatten out in 2013. I think that there will be some rebuilds and mixed use – where retail is going into the first floor of an apartment building – in the office and retail markets.

1. More Energy-Efficient Controls and Mechanical Systems;

Technology will continue to be a driver whether through regulatory edicts or from companies looking at their own bottom lines. I think that there will be continuing pressure from public agencies, landlords and image-conscious building owners to adopt more energy-efficient controls and mechanical systems. We will continue see mandates and incentives imposed by different states or by the federal government on the buildings they lease or put up for their own uses. Collectively private owners will be looking for technologies that can deliver a payoff.

1. Increase in Warehouse and Data Center Markets;

I think there are two smaller markets that are going to remain active that have implications for HVAC. The warehouse market will continue to grow with large, very efficient warehouses being located close to metropolitan areas. And data centers with their very intense cooling needs continue to be a strong growth niche for HVAC.

Emil Salazar

Market Analyst

SBI Energy

1. Product Development for Zero-Energy Buildings;

HVAC system manufacturers and integrators to devote more product 

development, 

to zero-energy and net zero-energy buildings: Designing a building in such a way 

that energy efficiency and on-site production convert it from an energy consumer 

to an energy producer lies at the heart of the zero-energy building (ZEB) concept. 

A ZEB is a building that produces as much energy as it uses when measured at 

the site. For ZEBs to flourish, HVAC manufacturers and designers must better 

integrate systems into buildings that may be significantly different from most 

modern building designs. Engineers will need the tools to design and apply better 

integrated equipment, manufacturers will need to produce ultra-high efficiency 

equipment and know how to best apply it to buildings, and both will have need to 

provide comfortable living conditions. Where possible, the incorporation of power 

from renewable energy sources also adds efficiencies to HVAC and electrical 

systems.

1. Growth in Internet-Enabled Sensor and Control Devices;

Sensor and control devices – particularly internet-enabled platforms – represent high-growth opportunities for HVAC manufacturers, vendors and installers: Proliferation of sensor and control devices that improve energy efficiency are other green product sales opportunities many HVAC manufacturers will capitalize on throughout 2013. Consumers will ramp up installations of household devices that afford more control of their heating and cooling temperatures and enable them to reduce energy loss and improve how they manage their thermal environment. They will also look to install smart control and monitoring devices that streamline HVAC performance from a central or remote location. Look for 10% market growth in internet-enabled HVAC monitoring devices to reach a 2013 U.S. market size of over $500 million.

1. Increase in Indoor Air Quality (IAQ) Products;

HVAC manufacturers seize opportunities in the IAQ product market: HVAC manufacturers are exploring opportunities in indoor air quality (IAQ) products that are more efficient and environmentally friendly. Newer HVAC technologies provide extra comfort and better air purification while reducing operating costs and lowering the environmental footprint. IAQ products give manufacturers the ability to diversify their product offerings and promote themselves as green businesses. I expect IAQ technologies will create ancillary revenue streams for leading HVAC manufacturers willing to invest capital in expanding their product lines and pursue this burgeoning market opportunity which includes applications such as duct cleaning, air filtration, and anti-microbial fogging (sanitizing the air). The overall US market for Indoor Air Quality products including double scroll compressors, inverter technologies and smart cooling fans and refrigerants is expected to reach nearly $8 billion in 2013 – representing a major market opportunity for HVAC manufacturers.

Christopher Burney

Executive Director of Planning, Design, and Construction

University of Mississippi Medical Center

1. Better Bacterial/Fungal Management;

I think that the industry has had a good handle on bacterial control in air systems 

for a long time. However, I do think that there is a growing problem (No pun 

intended) with fungal contamination. So much of it is within the structure and 

there are very few ways to control once it starts. I see the keys to this as better 

basic maintenance and better control of details during construction. Weep holes 

and flashing details must be carefully constructed, and we all need to remember 

that caulk, no matter who the manufacturer is, is never a life time product. If we 

can prevent the constant wetting of products, then there is little chance that mold 

will grow.

1. Increase in Self-Reliant HVAC Systems;

There is a growing awareness that had its genesis in Hurricane Katrina that for those of us who are involved in industries that cannot shut down, we have to adopt the creed that “We will be alone.” So we must move toward the ability to maintain operations while receiving no support from the outside. This includes the ability to reliably generate on-site power, maintain an adequate onsite, protected supply of fuel, and to be able to feed and house our captive workers and in the case of hospitals, patients.

1. Emphasis on Technical Education and Training;

Where I really see a problem is the aging of the workforce. There are so many incredibly talented trades people that are now in their 50s and approaching retirement and the talent pool to replace them is thin. As a society, we have to put an emphasis on the value of technical education and training or there will not be enough plumbers, steam fitters, machinists, or electricians.